Engine Coolant Thermostat Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

### Removal Procedure 2.4L

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the coolant until the coolant level is below the thermostat. Recover the coolant. Refer to Cooling System Draining and Filling .
3. Remove the exhaust manifold heat shield.
4. Remove the radaitor outlet bolts (1).
5. Remove cover to the outlet pipe through exhaust manifold runners.
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Disconnect the radiator outlet hose (1) and the clamp (2) from the radiator outlet pipe (3).
8. Remove the radiator outlet pipe (1) to oil pan (2) bolt (3).
9. Remove the cover to the outlet pipe bolt.
10. Remove the thermostat (2) and the seal (1) from the outlet pipe (3).
11. Clean the mating surfaces of the radiator outlet pipe and the coolant pump cover.

### Installation Procedure

1. Install the thermostat (2) and the seal (1) to the radiator outlet pipe (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the radiator outlet pipe (1) to oil pan (2) bolt (3).

Tighten
Tighten the outlet pipe to oil pan bolt to 26 N·m (19 lb ft).

3. Connect the outlet pipe to the oil pan bolt.

Tighten
Tighten the oil pan to 26 N·m (19 lb ft).

4. Install the radiator hose (1) and clamp (2) to the outlet pipe (3).
5. Lower the vehicle.
6. Install the cover (2) to the outlet pipe bolt (1) through the exhaust manifold runner.
7. Install the exhaust manifold heat shield.
8. Fill the cooling system. Refer to Cooling System Draining and Filling .
9. Connect the negative battery cable.
10. Inspect for leaks.